Fuel Tank Removal and Installation

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL CAUSING PERSONAL INJURY OR A FIRE HAZARD.
^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION EQUIPPED VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING THE AIR SUSPENSION SWITCH LOCATED IN THE LUGGAGE COMPARTMENT ON THE LEFT SIDE TO THE OFF POSITION. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

1. Disconnect the battery ground cable.
2. Relieve the system pressure.
3. Drain the fuel tank.







4. Remove the screws.
5. Raise the vehicle.
6. Remove the fuel tank filler pipe from the fuel tank.







7. Disconnect the fuel pump connector which is located above the No.4 crossmember.







8. Disconnect the fuel lines.







9. Disconnect the vapor tube from the tee on the RH side of vehicle.







10. Disconnect the vapor tube from the canister tube.
11. Position safety support under the fuel tank.







12. Remove the nuts and swing the fuel tank support straps away from the fuel tank.
13. Lower the fuel tank.
14. Remove and discard the fuel tank mounting studs.

INSTALLATION

NOTE: If tank is being replaced, the vapor control valve and fuel pressure transducer can be reused on the new tank.

1. Position the fuel tank in the vehicle.







2. Position the fuel tank support strap, install the new studs and tighten the new stud nuts.







3. Break off the stud shanks (N808979-S191).







4. Connect the vapor canister line and install a new clamp.







5. Connect the vapor line to the tee.







6. Connect the fuel lines.

NOTE: When connecting the fuel lines, make sure to connect the supply line first. The supply line has a label on it and is the upper line.







7. Connect the fuel pump connector.
8. Install the fuel tank filler pipe.